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Manual handling assessment
charts (the MAC tool)
Introduction
Work-related
musculoskeletal
disorders
(MSDs),
including
manual
handling
injuries,
are
the
most
common
type
of
occupational
ill
health
in
the
UK.
It
is
important
to
remember
that:
Q there
is
a
lot
you
can
do
to
prevent
them;
Q preventative
measures
are
often
simple
and
cost-effective;
Q you
cannot
prevent
all
MSDs,
but
where
they
occur,
early
reporting
of
symptoms,
proper
treatment
and
suitable
rehabilitation
are
essential.
The
Manual
Handling
Assessment
Charts
(MAC)
is
a
tool
aimed
at
employers,
This
is
a
web-friendly
health
and
safety
managers
and
safety
representatives
and
is
used
by
health
and
version
of
leaflet
safety
inspectors.
The
tool
will
help
you
assess
the
most
common
risk
factors
in
INDG383(rev3),
lifting
(and
lowering),
carrying
and
team
handling
operations
and
was
developed
to
published
11/18
identify
high-risk
manual
handling.
It
will
point
you
towards
the
factors
you
need
to
modify
to
control
these
risks.
What does the law say?
The
Manual
Handling
Operations
Regulations
1992
set
out
a
clear
hierarchy
of
measures
for
dealing
with
risk
likely
to
cause
harm
from
manual
handling.
These
are:
Q avoid
hazardous
manual
handling
operations
so
far
as
reasonably
practicable;
Q assess
any
manual
handling
operations
that
cannot
be
avoided;
Q reduce
the
risk
of
injury
to
as
low
as
reasonably
practicable.
Structure of the MAC
There
are
three
types
of
assessment
that
can
be
carried
out
with
the
MAC:
Q lifting
operations
(pages
3-7);
Q carrying
operations
(pages
8-12);
Q team
handling
operations
(pages
13-17).
For
each
type
of
assessment
there
is
an
assessment
guide
and
a
flow
chart.
There
is
a
score
sheet
to
complete
at
the
end
of
the
tool.
When not to use the MAC
Using
the
MAC
is
not
appropriate
for:
Q manual
handling
operations
involving
pushing
and
pulling
(see
the
Risk
Assessment of Pushing and Pulling (RAPP) Tool¹);
Q assessing
people
handling
(see
HOP6
The guide to the handling of people:
A systems approach²);
Q assessing
workplace
risks
associated
with
upper
limb
disorders
(see
Assessment of Repetitive Tasks of the upper limbs (the ART tool)³).
Page
1
of
20
Health and Safety
Executive
How
to
complete
a
MAC
assessment
Note: Using
the
MAC
may
not
comprise
a
‘suitable
and
sufficient’
risk
assessment.
You
may
need
to
do
a
full
risk
assessment
when
certain
conditions
apply.
Before
you
start
your
MAC
assessment,
look at the checklist
on
the
score
sheet
to
see
if
any
of
them
apply
to
you.
The
Appendix
of
Manual handling
4
(L23)
explains
this
in
more
detail.
G = GREEN - Low level of risk
Although
the
risk
is
low,
consider
the
exposure
levels
for
vulnerable
groups
such
as
pregnant
women,
disabled,
recently
injured,
young
or
inexperienced
workers.
A = AMBER - Medium level of risk
Examine
tasks
closely.
R = RED - High level of risk
Prompt
action
needed.
This
may
expose
a
significant
proportion
of
the
working
population
to
risk
of
injury.
P = PURPLE - Unacceptable level of risk
Such
operations
may
represent
a
serious
risk
of
injury
and
must
be
improved.
Q Identify
the
tasks
to
assess.
Choose
the
ones
that
you
know
are
hard
work
or
that
employees
complain
about.
Q Consult
employees
and
their
representatives
on
the
manual
handling
risks
from
their
work
and
ways
to
manage
and/or
control
these
risks.
See
5
INDG232
for
more
information.
Aim
to
gain
insight
into
the
demands
of
the
job
from
the
perspectives
of
all
employees
carrying
out
the
task.
Q Observe
the
task
carefully
(videoing
may
help)
and
make
sure
that
you
look
at
how
it
is
normally
done.
Q Select
the
appropriate
type
of
assessment
(lifting,
carrying
or
team
handling).
If
a
task
involves
lifting
and
carrying,
consider
both.
Q Follow
the
appropriate
assessment
guide
and
flow
chart
to
determine
the
level
of
risk
for
each
risk
factor.
Always
assess
the
worst-case
scenario
if
unsure.
Q Enter
the
colour
bands
and
numerical
scores
on
the
score
sheet
and
use
them
to
identify
which
risk
factors
need
to
be
examined
and
the
total
level
of
exposure
to
risk.
Q An
interactive
score
sheet
is
at
www.hse.gov.uk/msd/mac/scoresheet.htm.
Q Look
for
ways
of
modifying
the
task
to
reduce
the
red
risk
factors
to
amber
or
green
and
to
reduce
amber
risk
factors
to
green.
Q If
the
individual
does
a
number
of
tasks,
assess
each
one
separately.
Q Prioritise
action
by
addressing
the
task
with
the
highest
total
score
first.
The
total scores do not relate to specific action levels.
Look
at
www.hse.gov.uk/msd/mac
for
further
guidance
on
using
this
tool.
Remember: The
purpose
of
the
assessment
is
to
identify
and
then
reduce
the
overall
level
of
risk
of
the
task.
You
need
to
put
measures
in
place
to
control
the
risks
you
have
identified.
There
is
space
to
list
your
control
measures
on
the
score
sheet.
Manual
handling
assessment
charts
(the
MAC
tool)
Page
2
of
20
Health and Safety
Executive
Lifting
operations
assessment
guide
A Load weight/frequency
Note
the
weight
of
the
load
and
the
frequency
(or
repetition
rate)
of
the
lifting
operation.
Read
the
risk
band
from
the
graph
below
and
enter
the
colour
band
and
numerical
score
onto
the
score
sheet.
If
the
colour
band
is
purple
you
should
examine
the
task
very
closely
as
it
may
represent
a
serious
risk
of
injury
and
must
be
improved.
Load weight/frequency graph for lifting operations
50 P=10 50
40 R=6 40
30 30
20 A=4 20
eight of load (kg)
W
10 G=0 10
0 0
One lift per 30 minutes 5 minutes 2 minutes 1 minute 14 seconds 9 seconds 5 seconds
day (2) (12) (30) (60) (250) (400) (720)
One lift every (lifts per hour)
To
assess
lifting
at
more
than
once
every
five
seconds
you
should
carry
out
a
full
risk
assessment.
Repetitive
handling
of
light
items
will
fall
within
the
green
zone,
but
may
be
associated
with
upper
limb
problems.
For
advice
on
assessing
these
tasks
see
6
Upper limb disorders in the workplace
and
the
ART
tool.
When
a
job
is
complex
because
load
weights
vary
significantly
(eg
in
order
picking/
distribution)
you
can
use
the
Variable manual handling assessment chart
(V-MAC)
tool7
to
assess
the
load
weight/frequency
risk
factor
instead
of
this
graph,
before
returning
to
complete
your
MAC
assessment.
Manual
handling
assessment
charts
(the
MAC
tool)
Page
3
of
20
Health and Safety
Executive
Lifting
operations
assessment
guide
B Hand distance from the lower back
Observe
the
horizontal
distance
between
the
worker’s
hands
and
lower
back.
You
should
assess
the
‘worst-case
scenario’,
including
picking
up
and
putting
down.
Use
the
following
illustrations
and
descriptions
as
a
guide:
Upper
arms
vertical
AND
Upper
arms
angled
Torso
bent
Torso
upright.
Upper
arms
angled
torso
upright
away
from
torso
forward
Arms
fully
away
from
torso
AND
outstretched
torso
bent
forward
Hands
close
to
G/0
Hands
at
moderate
A/3
Hands
far
from
the
low
back
R/6
the
low
back
distance
from
the
low
back
C Vertical lift zones
Observe
the
vertical
position
of
the
worker’s
hands
at
both
the
start
and
end
of
the
lift.
Record
the
‘worst-case’
colour
band/score.
Use
the
following
illustrations
and
descriptions
as
a
guide:
Hands
Hands
between
Hands
Hands
at
floor
level
Hands
at
between
knee
and
floor
between
or
below
head
height
knee
and
G/0
level
elbow
A/1
or
above
R/3
elbow
height
and
height
head
height
Manual
handling
assessment
charts
(the
MAC
tool)
Page
4
of
20
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